Zinn & The Art of Mountain Bike Maintenance

Zinn & the Art of Mountain Bike Maintenance, 5th edition
Text copyright 2010 by Lennard Zinn

Illustrations copyright 2010 by VeloPress
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Cover and interior design by Erin Johnson

Composition by Erin Johnson and Jessica Xavier
Cover photo by Brad Kaminski; bike built by Lennard Zinn
Custom paint job on cover bike by Spectrum Powder Works, Colorado Springs, CO
Title font Sign Production JNL; body text Caecilia Roman
10
11
12 / 11
10
CONTENTS
A Tip of the Helmet to . . .
Introduction
ix
xiii
Chapters
1
Tools
Basic Stuff: Preride inspection, wheel removal,

and general cleaning
15
Emergency Repairs: How to get home when

something big breaks or you get lost or hurt
33
Chains
51
Transmission: Front and rear derailleurs, cables,

and shifters
71
Wheels: Tires, rims and spokes, hubs, cassettes,

and freewheels
111
Brakes: Cables, levers, and calipers
147
Cranksets
195
Pedals
225
10
Saddles and Seatposts
243
11
Handlebars, Stems, and Headsets
257
12
Wheelbuilding
291
13
Forks
311
14
Frames
347
Appendixes
A
Troubleshooting Index
371
Gear Development
377
Mountain Bike Fitting
383
Torque Table
393
Glossary
409
Bibliography
421
Index
423
Illustration Index
433
About the Author and Illustrator
437
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
INTRODUCTION
Peace of mind isnt at all superficial, really. Its the

whole thing. That which produces it is good maintenance; that which disturbs it is poor maintenance.
What we call workability of the machine is just an
objectification of this peace of mind. The ultimate
tests always your own serenity. If you dont have this
when you start and maintain it while youre working,
youre likely to build your personal problems right into
the machine itself.
Robert M. Pirsig,
Zen and the Art of Motorcycle Maintenance
ABOUT THIS BOOK
ticular way, and to have one without the other
This book is intended for people who have an
would be missing out on half the fun.
interest in maintaining their own mountain
The romantic can appreciate how success at
bikes. I have written it for mountain bike owners
bike mechanics requires that the procedures be
who do not think theyre capable of maintain-
done with love, without which the care you imag-
ing their own bikes, as well as for those who do
ined putting into your mountain bike would be
and who want the how-to details at their finger-
lost. And even the pure romantic can follow the
tips. In Zen and the Art of Motorcycle Maintenance,
simple step-by-step procedures and exploded
Robert Pirsig explores the dichotomy between
diagrams in this book (of which Fig. I.1 is an
the purely classical and purely romantic views
extreme example and is the only one not intended
of the world, a dichotomy that also applies to
to be simple and clear!) and discover a passion for
mountain biking. Riding a mountain bike is
spreading new grease on old parts.
generally a romantic experience of emotion,
Zinn & the Art of Mountain Bike Maintenance is
inspiration, and intuition, even when solving the
organized in such a way that you can pick main-
complex physics of how to negotiate a technical
tenance tasks appropriate for you. The repairs in
section of trail without putting your foot down.
these pages require no special skills to perform;
Mountain bike mechanics, however, is a purely
anyone can do them. It takes only a willingness
classical structure of underlying form dominated
to learn.
by reason and physical laws. The two practices
Mountain bikes are admirably resilient mach-
bike riding and bike maintenancefit eloquently
ines. You can keep one running a long time just
together. Each is designed to function in a par-
by changing the tires and occasionally lubricating
xiii
xiv
the chain. Chapter 2 is about the most minimal
my bike that I do not understand well enough to
maintenance your bike requires. Even if that is
know whether it is likely to last the ride or how to
the only part of this book you end up using, youll
fix it if it does not.
have gotten your moneys worth by avoiding some

unpleasant experiences out on the trail.
There is an aspect of bicycle mechanics

that can be extremely enjoyable in and of itself,
This book was originally intended for home
almost independent of riding the bike. Bicycles
enthusiasts, not shop mechanics. For that reason,
are the epitome of elegant simplicity. Bicycle
I have not included the long and precise lists of
parts, particularly high-end components, are
parts specifications that a shop mechanic might
meant to work well and last a long time. With the
need. Nonetheless, when combined with a speci-
proper attention, they can shine both in appear-
fication manual, this book can be a useful, easy-
ance and in performance for years to come.
to-follow reference for shop mechanics, too.
There is real satisfaction in dismantling a filthy

part that is not functioning well, cleaning it up,
WHY DO IT YOURSELF?
lubricating it with fresh grease, and reassembling
There are a number of reasons why you would
it so that it works like new again. Knowing that
want to maintain your own mountain bike.
I made those parts work so smoothlyand that I
Obviously, if done right, it is a lot cheaper to do
can do it again when they get dirty or wornis
yourself than to pay someone else to do it. This is
rewarding. I am eager to ride hard to see how
certainly an important factor for those riders who
they hold up rather than being reluctant to ride
live to ride and have no visible means of support.
for fear of breaking something.
Self-maintenance is a necessity for that crew.
Also, if you share my stubborn unwillingness
As your income goes up and the time available
to throw something out and buy a replacement
to maintain your bike goes down, this becomes
simply because it has quit workingbe it a leaky
less and less true. If youre a well-paid profes-
Waterpik; a torn tent; a duffle bag with a broken
sional with limited free time, it probably does
zipper; or an old car, dishwasher, clock, or chain-
not make as much economic sense to maintain
saw that is no longer running wellthen this
your own bike. Yet you may find that you enjoy
book is for you. It is satisfying to keep an old piece
working on your bike for reasons other than
of equipment running long past its time, and its a
just saving money. Unless you have a mechanic
great learning experience!
whom you trust and to whom you take your bike
There is also something very liberating about
regularly, you are not likely to find anyone else
going on a long ride and knowing that you can
who cares as much about your bicycles smooth
fix just about anything that might go wrong with
operation and cleanliness as you do. You may also
your bike out on the trail. Armed with this knowl-
need your bike fixed faster than a local shop can
edge (which begins with learning to identify the
do during its busy season. And you need to be
parts of a mountain bike, shown in Fig. I.2) and
able to fix mechanical breakdowns that occur on
the tools to put it into action, you will have more
the trail.
confidence to explore new areas and to go farther
It is a given: Breakdowns will happen, even
than you might have otherwise.
if you have the worlds best mechanic working
To illustrate, an experience from way back in
on your bike. For this reason, it takes away from
1995 comes to mind, when I took a day to ride
my enjoyment of a ride if I have something on
the entire 110-mile White Rim Trail loop in Utahs
ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE

Canyonlands National Park. It is as desolate as
possible. Exploded diagrams are purposefully
you can imagine out there, and I was completely
used instead of photographs to show more clearly
alone with the sky, the sun, and the rocks for long
how each part goes together. The first time you
stretches. I had a good mileage base in my legs, so
go through a procedure, you may find it easier to
I knew I was physically capable of doing the ride
have a friend read the instructions out loud as you
during the limited daylight hours of late October.
perform the steps.
I had checked, replaced, or adjusted practically
Obviously, some maintenance tasks are more
every part of my bike in the days before the ride.
complicated than others. I am convinced that
I had also tried out the bike on long rides close to
anyone with an opposable thumb can perform
town. Finally, I added to my saddlebag tool kit a
virtually any repair on a bike. Still, it pays to spend
few tools that I do not ordinarily carry.
some time getting familiar with the really simple
I knew that there was very little chance of
tasks, such as fixing a flat, before throwing your-
anything going wrong with my bike, and with the
self into complex jobs, such as building a wheel.
tools I had, I could fix almost anything short of a

broken frame on the trail. Armed with this knowledge and experience, I really enjoyed the ride! I
stopped and gawked at almost every breathtaking vista, vertical box canyon, colorful balanced
rock, or windblown arch. I took scenic detours.
I knew that I had a good cushion of safety, so I
xv
e LEVEL 1
e e LEVEL 2
e e e LEVEL 3
could totally immerse myself in the pleasure of
Tasks and tools required are divided into
the ride. I had no nagging fear of something going
three levels indicating their complexity or your
wrong to dilute the experience.
proficiency. Level 1 tasks need level 1 tools and
Confidence in your mechanical ability allows
require of you only an eagerness to learn. Level 2
you to be more courageous about what you will try
and level 3 tasks also have corresponding tool sets
on trails. And armed with this confidence youll
and are progressively more difficult. All repairs
be more willing to share your love of the sport
mentioned in this book are classified as level 1
with less experienced riders. Bringing new people
unless otherwise indicated. Tools are shown in
along on rides is a lot more fun if you know that
Chapter 1. The section at the end of Chapter 2,
you can fix their bikes and they wont be stranded
Performing Mechanical Work: A General Guide
with an old junker that wont roll.
(ii-17), is a must-read; it states general policies

and approaches that apply to all mechanical work.
Each chapter starts with a list of required tools
Skim through the entire book. Skip the detailed
in the margin. If a section involves a higher level
steps, but look at the exploded diagrams and get
of work, there will be an icon designating the level
the general flavor of the book and whats inside.
and tools necessary to perform the tasks in that
When it is time to perform a particular task,
section. Tasks and illustrations are numbered for
youll know where to find it, and youll have a
easy reference. Section references use the sym-
basic idea of how to approach it.
bol . For instance, iii-6 means see Section
Illustrator Todd Telander and I have done our

best to make these pages as understandable as
iii-6 in Chapter 3. Illustrations are referred to as

Figures, for instance, Fig. 3.3.
INTRODUCTION
I NT R O D UC TI O N
HOW TO USE THIS BOOK
xx
and 650B (27.5-inch) tires and wheels are gaining
your bike will transform itself from a mysterious
favor, particularly for tall riders. Smaller 24-inch
contraption seemingly too complicated to tamper
wheels and tires are found on small mountain bikes.
with to a simple, very understandable machine
Tire widths and shapes vary and include everything
that can be a genuine delight to work on. Just
from studded snow tires to smooth street tires. This
allow yourself the opportunity and the dignity to
book also covers hybrid bikes (Fig. I.5), which are a
follow along, rather than deciding in advance that
cross between road bikes and mountain bikes.
you will never be able to do this. All you have to
No matter how a mountain bike is configured,
do is follow the instructions and trust yourself.
even those who see themselves as having no
So, set aside your self-image as someone who
mechanical skills will be able to tackle problems
is not mechanically oriented (and any other fac-
as they arise if they study the steps necessary
tors that may stand in the way of your making
to properly maintain and repair their bike. With
your mountain bike ride like a dream), and lets
a little bit of practice and a willingness to learn,
start playing with your bike!

TOOLS
Behold, we lay a tool here and on the morrow it is gone.

The Book of Mormon
ou cant do much work on a bike without
expensive), and they ensure that your riding bud-
tools. Still, its not always clear exactly which
dies will show up not only to ask your sage advice,
tools to buy. This chapter clarifies the tools you

should consider owning on the basis of your level
of mechanical experience and interest.
but also to borrow your tools.

And if you really want to go all out and be set
up like a pro (and even have mechanics wanting
As I mentioned in the Introduction, the main-
to borrow your tools), you can splurge on the set
tenance and repair procedures in this book are
shown in Figure 1.4. If you loan tools, you might
classified by their degree of difficulty. Nearly all the
consider marking your collection to help recover
repairs in this book are classified as level 1, unless
those items that might otherwise take a long
otherwise indicated. The tools for levels 1, 2, and 3
time finding their way back to your workshop.
are pictured and described in the following pages.
It wouldnt hurt writing down the details about
Lists of the tools needed in each chapter are shown
which tool you lent to whom and on what date.
in the margin at the beginning of each chapter.
You would be surprised how easy it is to forget
For the uninitiated, there is no need to rush

out and buy a large number of bike-specific tools.
who has one of your seldom-used tools such as

snapring pliers or a metric tap.
With only a few exceptions, the Level 1 Tool Kit
i-1
(Fig. 1.1A) consists of standard metric tools. This

kit is similar to the collection of tools I recommend later in this chapter to carry with you on
LEVEL 1 TOOL KIT
rides, though in a more compact and lightweight
e LEVEL 1
form (Figs. 1.56). The Level 2 Tool Kit (Fig. 1.2)
Level 1 repairs are the simplest and do not
contains several bike-specific tools, allowing you
require a workshop, although it is nice to have a
to do more complex work on the bike. The tools
good space to work. You will need the following
in the Level 3 Tool Kit (Fig. 1.3) are extensive (and
tools (Fig. 1.1A):
Tire pump with a gauge and a valve head
1.1A
Level 1 Tool Kit
to match your bikes tubes (either Presta or

Schrader valvessee Fig. 1.1B; most good pumps
will fit both). A spare rubber valve-seal insert for
the head is a good idea; these wear out.
Standard screwdrivers: small, medium, and
chain tool
large (one of each).
tire levers
Phillips-head screwdrivers: one small and one

medium.
Set of three plastic tire levers (Figs. 6.56).
At least two spare tubes of the same size and
15mm pedal wrench
valve type as those on your bike.

Container of regular talcum powder. It works
well for coating tubes and the inner casings
of tires. Do not inhale this stuff; its bad for
the lungs.
grease
Patch kit. Choose one that comes with sandpaper instead of a metal scratcher and patches
with soft orange rubber backing to the black
rubber (Fig. 6.11). At least every year and a half,
chain lube
check that the glue has not dried up, regardless of whether the tube has been opened or
spare tube
not. On rides, you might as well take a little

packet of glueless patches; they dont work as
well as standard patches, but if the glue has
dried up, youll be glad you have them.
One 6-inch adjustable wrench (aka Crescent
wrench).
plenty of rags
patch kit
Pliers: regular and needle-nose.

Set of metric hex keys (aka Allen wrenches
or hex wrenches) that includes 2.5mm, 3mm,
4mm, 5mm, 6mm, 8mm, and 10mm sizes.
modern shock pump
Folding sets are available and work nicely to

keep your wrenches organized but are not
strong enough or long enough in the big sizes
(6mm and up); big bolts require more leverage.
15mm pedal wrench. This is thinner and lon-
I also recommend buying extras of the 4mm,
ger than a standard 15mm wrench and thicker
5mm, 6mm, and 8mm sizes.
than a cone wrench (Fig. 9.3). Your bikes ped-
Set of metric open-end/box-end wrenches

that includes 7mm, 8mm, 9mm, 10mm, 13mm,
14mm, 15mm, and 17mm sizes.

als may accept only a 6mm or 8mm hex key

(Fig. 9.4), so you may not need this tool.
Chain tool for disconnecting and reconnecting
3
chain-elongation gauge
spoke wrench
noggin
standard and Phillipshead screwdrivers
tire
pump
with
gauge
talcum
powder
6" adjustable wrench
rubbing
alcohol
pliers
talc
rubbing alcohol
metric hex
keys
folding metric
hex keys
Schrader valve adapter

for old Marzocchi and
RockShox forks
metric open-end/box-end wrenches

needle-nose
pliers
1.1B
chains (Figs. 4.1011). Older chain tools may
Valve types
Presta
be too wide for the narrow chains on newer

bikes; read the Pro Tip in Chapter 4 before
buying one.
Schrader
tion of the chain (Figs. 4.56).
CHAPTER 1
T O O LS
Chain-elongation gauge to monitor the condi-
Spoke wrench to match the size of nipples
1.2
Level 2 Tool Kit
used on your bikes wheels.

Tube or jar of grease. I recommend using
ball-peen hammer
grease designed specifically for bicycles; however, standard automotive grease is okay,
except in suspension forks and twist shifters.
portable bike
stand
Drip bottle or can of chain lubricant (Fig. 4.1).

Please choose a nonaerosol; it is easier to
control, uses less packaging, and wastes less
in overspray.
Rubbing alcohol for cleaning disc-brake pads,
rotors, shocks, and internal parts and for
removing and installing handlebar grips.
A lot of rags!
Channel-lock
pliers
splined pedalspindle removal

tool
Other useful items:

If you have an air-sprung suspension fork or
rear shock, you need a shock pump. Get one
with a no-leak head if the front or rear shock
snapring
pliers
has standard Schrader valves (Fig. 13.10),

and get the adapter you need if your bikes
fork requires either a ball needle or a special adapter to insert down inside a sunken
Schrader valve.
i-2
LEVEL 2 TOOL KIT
e e L E V EL 2
Level 2 repairs are a bit more complex, and I
recommend that you create a well-organized
workspace with a shop bench. Keeping your workspace organized is probably the best way to make
rubber gloves
duct tape
maintenance and repair easy and quick. You will

need the entire Level 1 Tool Kit (Fig. 1.1A) plus the
following tools (Fig. 1.2):
tire pressure
gauge
% Portable bike stand. Be sure that the stand is

sturdy enough to remain stable when youre
really cranking on the wrenches. If for some
reason you cant clamp your bikes seatpost,
you will need a bike stand that holds the bike
by the bottom bracket and the front or rear end
with one wheel out; see the one in Figure 1.4.

sound system
CHAINS
A chain is only as strong as its weakest link.
Anonymous
A sausage is only as good as its last link.
TOOLS
Bluto
chain lubricant
12-inch ruler
chain tool
lots of rags
bike chain is a simple series of links connected
fancy about it, you can assess the type of condi-
by rivets. Rollers surround each rivet between
tions in which you ride and choose a lubricant
the link plates and engage the teeth of the cogs
intended for those conditions. Some lubricants
and chainrings. It is an extremely efficient method
are dry and pick up less dirt in dry conditions.
of transmitting mechanical energy from the ped-
Some are sticky and therefore less likely to
als to the rear wheel. In terms of weight, cost, and
wash off in wet conditions. Still others claim to
efficiency, the bicycle chain has no equal, and
be metal conditioners that actually penetrate
believe mepeople have tried without success to
and alter the surface of the metal. One of these,
improve on it for years.
ProGolds ProLink, gives me longer chain life in all
rubber gloves
OPTIONAL
chain-elongation
indicator
master link pliers
solvent (citrus
based)
To keep your bike running smoothly, you have
riding conditions, with daily use, than anything
self-contained chain
cleaner
to take care of the chain. It needs to be kept clean
else I have tried, so thats what I use. Im not say-
old water bottle
and well lubricated in order to transmit your
ing that there arent other equally good products,
caliper
energy efficiently and shift smoothly. Chains need
but by recommending one that I know is good,
pliers
to be replaced frequently to prolong the working
I can cut down on the e-mails asking me what
solvent tank
life of other, more expensive, drivetrain compo-
chain lube I suggest.
Rohloff cog-wear
indicator
nents because a chain gets longer as its internal
Chain lubes generally come in spray cans and
parts wear, thus contacting the gear teeth differ-
in squeeze bottles. Sprays should be avoided for
ently than intended.
regular maintenance chores because they tend

to spew too much oil over everything, includ-
CHAIN SERVICE AND ASSEMBLY
ing in the air where you can inhale the lube. The
chain needs oil only between contacting parts.
iv-1
On the outside, a thin film is sufficient to keep
LUBRICATING THE CHAIN
corrosion at bay; more than that will only attract
When lubricating the chain, use a lubricant
dirt and gunk without improving the function of
intended for bicycle chains. If you want to get
the chain.
51
52
4.1
Lubing the chain
2. Wipe the chain off lightly with a rag. In wet

conditions, expect to use more lubricant (after
every ride or even during a long, rainy ride).
iv-2
CLEANING THE CHAIN BY FREQUENT
WIPING AND LUBRICATION
Cleaning the chain can be accomplished in
a number of ways. The simplest method to
maintain a chain is to wipe it down frequently,
lubricate it, and then wipe off the excess lube. If
1. Drip a small amount of lubricant across each
you do this procedure before every ride, you will
roller (Fig. 4.1). Periodically move the chain so
never need to clean the chain with a solvent.
that you can easily access the links you are
The lubricant softens the old sludge buildup,
working on. To speed the process, turn the
which is driven out of the chain when you
crank slowly while dripping lubricant onto
ride. Of course, the lubricant also picks up new
the chain as it goes by. Yes, this method will
dirt and grime, but if you wipe them off before
cause you to apply excess lubricant, which
theyre driven deep into the chain and relubri-
will pick up more dirt. But overlubricating is
cate the chain frequently, it will stay clean and
far preferable to not lubricating, and if you
supple. Chain cleaning can be performed as fol-
wipe and lube the chain after each ride or
lows with the bike standing on the ground or in
two, it wont build up excessive grime.
a bike stand:
4.2
Wiping the chain with a rag

4.3
Wiping the jockey wheels with a rag
4.4
Using a solvent-bath chain cleaner
53
1. Grab the chain with a rag. Grasp the lower
made of clear plastic and have two or three
length of the chain (between the bottom of
rotating brushes that scrub the chain as it moves
the chainring and the rear-derailleur lower
through the solvent bath (Fig. 4.4). The units offer
jockey wheel).
the advantage of letting you clean the chain
2. Turn the crank backward a number of revo-
without removing it from the bike. Regularly
lutions. Pull the chain through the rag (Fig.
removing the chain shortens any chains life;
4.2). Periodically rotate the rag to present a
moreover, with 9- or 10-speed chains unless you
cleaner section of it to the chain.
use a master link, you may find that the chain
3. Lubricate the chain as in iv-1.

To encourage regular care, leave a pair of rub-
breaks under high load, thereby driving your foot,

and perhaps your entire body, into the ground.
ber gloves, a rag, and some chain lube next to your
Most chain-cleaning units come with a non-
bike. Then, whenever you return from a ride, put on
toxic, citrus-based solvent. For your safety, and
the gloves, wipe and lube the chain, and put your
other environmental reasons, I strongly recom-
bike away. It takes maybe a minute, your hands
mend that you purchase nontoxic citrus solvents
stay clean, and your bike is ready for the next ride.
for the chain-cleaning unit, even if it already
If you can find time to take a shower after you ride,
comes with a petroleum-based solvent. If you
you can find time for this. Wipe the chainrings,
recycle used diesel fuel, then go ahead and use it.
cogs, front derailleur, and jockey wheels (Fig. 4.3)
In any case, wear gloves and glasses when using
while youre at it, and the entire drivetrain will
any solvent.
Citrus chain solvents often contain some
always work ideally.
lubricants, so they wont dry the chain out. The

combination of lubricant and solvent is why diesel
USING CHAIN-CLEANING UNITS
fuel has had such a following as a chain cleaner.
Several companies make chain-cleaning units
A really strong solvent without lubricant (acetone,
that scrub the chain with a solvent while it is
for example) will displace the oil from inside the
on the bike. These chain cleaners are generally
rollers. The solvent will later evaporate, leaving a
CHAPTER 4
C H AI NS
iv-3
54
dry, squeaking chain that is hard to rehabilitate.
supplies special subpins for reassembly of its
The same can happen with a citrus-based solvent
chains that are meant to prevent this problem,
that does not include a lubricant if no lubricant is
but the chain is still not as strong there as if you
separately applied, especially if the chain is not
had left the original pin in place.
allowed to dry long enough. The procedure for

using a chain-cleaning unit is straightforward:
1. Remove the top and pour in the solvent up
A hand-opened master link can avoid the

problem of repeatedly opening and reassembling
the chain. Master links are standard on SRAM,
Wippermann, Taya, and KMC chains. An after-
to the fill line.

2. Place the chain-cleaning unit up against the
market master link, like Licktons SuperLink, can
bottom of the chain. Reinstall the top so that
also be installed into any chain so long as you
the chain runs through it (Fig. 4.4).
make sure that the master link is the right width.
3. Turn the bikes crank backward. Run the
If you do disassemble the chain (see iv-7
chain through the units brushes until it is
or iv-11 for instructions), you can clean it well,
clean.
even without a solvent tank. Just drop the chain
4. Remove the unit from the chain.
into an old jar or water bottle half filled with sol-
5. Lubricate the chain as in iv-1.
vent. Using an old water bottle or jar allows you
6. Let the solvent settle, decant the clear por-
to clean the chain without touching or breathing
tion, and discard the sludge.
the solventsomething to be avoided even when

you are using citrus solvents.
iv-4
REMOVING AND CLEANING THE CHAIN
The procedure for cleaning the chain without

using a chain-cleaning unit could not be simpler:
e L E V EL 1
1. Remove the chain from the bike (iv-7 or
You can also clean the chain by removing it from
2. Drop it in a water bottle or jar.
the bicycle and cleaning it in a solvent. I do not
3. Pour in enough solvent to cover the chain.
recommend this procedure unless the chain has
4. Shake the bottle vigorously. Keep it low to
a master link, because repeatedly disassembling
the ground in case the top pops off or the jar
the chain by pushing rivets in and out weakens it.
breaks.
Mountain bike chains are prone to breakage because of the conditions in which they are
used, but chain breakage is even more of an issue
because of the narrow width of 9- and 10-speed
iv-11).
5. Hang the chain to air-dry.

6. Reassemble it on the bike (see iv-8 to
iv-11).
7. Lubricate it as in iv-1.
chains. A chain that breaks during riding gener-
Whatever you do, dont leave the chain to
ally does so when you shift the front derailleur
soak for extended periods in citrus-based sol-
while pedaling hard. This technique can pry a
vents, because these are water based and will
link plate open so that the head of a rivet pops
cause the chain to oxidize (rust), making it move
out of the plate, tearing the chain apart. Chain
with more friction and be more prone to break-
disassembly and reassembly expand the size of
age. (Some people believe in having two chains
the rivet hole where you put the chain together,
they rotate on and off the bike, leaving one soak-
allowing the rivet to pop out more easily. Shimano
ing in solvent while the other one is on the bike.

Although this would work with diesel fuel as the
1,000 miles, especially for bikes ridden in dirty
solvent, it wont work with water-based solvents.
conditions by a large rider. Lighter riders riding
In any case, you gain nothing by soaking the chain
mostly on paved roads can often extend replace-
for extended periods, so just dont do it.)
ment time to more than 2,000 miles.
55
After removing the chain, allow the solvent
iv-6
in the bottle or jar to settle for a few days so that

you can decant the clear stuff and use it again. Ill
say this throughout the book: Use a citrus-based
CHECKING FOR CHAIN ELONGATION
solvent. It is not only safer for the environment;
e LEVEL 1
it is also gentler on your skin and less harmful
a. Chain-elongation gauges
to breathe. Wear rubber gloves when working
The simplest accurate method for checking chain
with any solvent, and use a respirator meant for
elongation is to use a gauge. Make sure you check a
volatile organic compounds if you are not using
number of spots on the chain; youll find variation.
a citrus-based solvent. There is no sense in fixing
The Rohloff gauge (Fig. 4.5) is simple, quick,
your bike to go faster if you end up becoming a
and reliable. Its a go/no-go gauge. Brace the hook
slow, sickly bike rider.
end against a chain roller, and if the opposing

curved tooth falls completely into the chain so
iv-5
REPLACING THE CHAIN
that the length of the tools body contacts it, the

chain is shot. If the chain is still in good shape, the
curved tooth will not go all of the way in. The tooth
LE VE L 1
marked S is for checking a chain running strictly
As the rollers, pins, and plates wear out, the
on steel rear cogs, and the tooth marked A is for
chain lengthens. That, in turn, hastens the wear
checking aluminum and titanium cogs, but I use
and tear on other drivetrain parts. An elongated
just the A side. I find that if the A edge comes down
chain concentrates the load on each individual
to the chain and I replace it right then, I get almost
gear tooth, rather than distributing it over all of
infinite life out of my chainrings and cogs, even
the teeth that the chain is wrapped around, and
titanium ones. Thats worth it to me.
as a result the gear teeth become hook-shaped
The ProGold chain gauge (Fig. 4.6) is also quick
and the tooth valleys become wider. If such wear
and accurate. Brace the hooked end against a
has already occurred, a new chain will not solve
chain roller, and let the long tooth drop into the
the problem. A new chain will not mesh properly with deformed teeth, and it is likely to skip
whenever you pedal hard. So before all of that
extra wear and tear hits your pocketbook, get in
the habit of checking the chain on a regular basis
4.5
Checking chain wear with the Rohloff gauge.

If the curved tooth with the S (steel cogs)
falls completely into the chain, replace the
chain (A is for aluminum cogs).
(iv-6) and replacing it as needed.

How long it takes for the chain to wear out
will vary, depending on chain type, maintenance,
riding conditions, and strength and weight of the
CHAPTER 4
C H AI NS
rider. Figure on replacing the chain every 500 to
198
Square taper, Octalink, and ISIS are three
tighten the push bolt, and you will damage
different bottom-bracket and crankarm interface
the threads. Future crank removal depends
standards. Square-taper bottom-bracket spindles are
on those threads being in good condition.
square on the end (Figs. 8.1, 8.18, 8.2123) and fit into
5. Tighten the push bolt clockwise (Fig. 8.6)
a square hole in the crankarm. The spindle ends are
until the crankarm pulls off the spindle. Use
tapered (at a 2-degree angle) to tighten into the crank
a socket wrench or the included handle.
as the arm is pushed into the spindle. ISIS (Fig. 8.19)
6. Unscrew the puller from the crankarm.
and Shimano Octalink (Fig. 8.20) are both oversized

hollow spindles (aka pipe spindles) with longitudinal
Installation
splines on the ends.
a. Integrated-spindle cranks with two pinch

bolts on the left arm
3. Unscrew the crank pullers (Fig. 8.6) center

push bolt so that its tip is flush with the
e LEVEL 1
face of the tool. Make sure the flat end of

the push bolt is the right size for the bottom
1. Grease the spindle tip and the bore of each
bracket; the push bolt end is much smaller
bearing.
for a square-taper spindle than for an ISIS or
2. Push the spindle (which is attached to the
a Shimano Octalink splined spindle.
right crankarm) in through the bearings from

the drive side.
4. Thread the crank puller into the hole in the

crankarm. Be sure that you thread it in (by
3. Slide the left arm onto the end of the spindle.
hand) as far as it can go; otherwise, you will
Check that the crank is at 180 degrees from
not engage sufficient crank threads when you
the right arm.
8.5 Removing and installing a Shimano 20072010 XTR FC-M970 crankset
spacer
spindle
right
bearing
cup
spacer
left bearing cup
spindle cover
with O-rings
left crankarm
(Attention: left-hand thread!)
right
crankarm
bolt
TL-FC35
crankarm
removal
tool
TL-FC17
adjusting
nut tool
bolt
washer retainer
washer

adjusting nut
INDEX
Adjustable cups, 207, 215, 216, 221,

409
Air compressors, 11, 122, 154
Air pressure, 318, 320, 326327
Air-sleeves, servicing, 353, 354, 355
Alignment tool, 10
Antiseize compound, 28, 200
Antitwist tool, 9
Automatic transmission uid (ATF),
336, 337
Axle-clamp tool, 10
Axle nuts, 15, 20
Axles, 30, 212, 299, 409
checking, 19
cleaning, 130
removing, 129
replacing, 235
securing, 2324
through-, 2022, 23, 128
Ball bearings, 142, 174, 203, 204,
207, 218, 231, 234, 358, 359,
360, 361, 409
angular-contact, 272, 277, 278,
279, 281
ceramic, 136, 217, 219
cleaning, 130131, 133, 221, 237,
277, 280
loose, 278, 279
lubricating, 131, 132, 281, 286
orienting, 218219, 278
overtightening, 272
press-in, 211, 279
replacing, 130, 131, 217220, 277,
280, 282, 359360
sealed, 416
standard, 280
steel, 136, 217
See also Cartridge bearings
Bar ends, 153, 154, 287, 409
installing, 9596, 255, 257
position of, 390391
replacing, 9596, 257, 258
Barrel adjusters, 77, 78, 88, 89, 90,
92, 93, 149, 151, 152, 153, 154,
166, 409
BBT-39 tool, 200, 212
Bearing cups, 207, 211, 212, 409
Bearing pullers, 211, 219220
Bearing removers, 11
Belt drives, 6466, 101
Bike dimensions, 385
Bike tting, 383391, 385393
Bike stands, 4, 9
Blankets, 14, 48
Body measurements, 385388
Bosses, 176, 180, 181, 183, 186, 188,
191, 194, 309
brake, 148, 150, 345, 348, 410
cantilever, 148, 311, 312, 313, 348,
350, 351, 411
disc-brake, 312, 313, 350, 351
Bottom-bracket cups, 30, 83, 213,
217, 223, 350
Bottom-bracket shells, 11, 58, 66, 81,
83, 207, 208, 209, 210, 212, 213,
214, 215, 216, 220, 222, 223,
252, 352, 387, 410
cleaning, 211, 212
full-carbon, 204
tapping, 350
unthreaded, 203
Bottom-bracket tools, 6
Bottom brackets, 65, 102, 108, 109,
110, 191, 195, 198, 203216, 231,
345, 388, 409
adjusting, 201, 222, 223
BB30: 220
BB86: 204, 205, 206
BB90: 204, 206
BB92: 204206, 210211, 220
BB95: 204206, 210211, 219
cartridge, 212213, 216, 220221,
223225
cup-and-cone, 213216, 221, 222,
223
eccentric, 58, 66
external-bearing, 203, 205, 206,
209210
height, 384, 386, 410
installing, 83, 208216, 221

integrated-spindle, 216, 217
ISIS, 198, 213
ISO, 206
noise in, 221224
overhauling, 109, 216221, 223
PF24: 205, 210211, 220
PF30: 204, 220
Shimano, 207, 209, 213, 215
square-taper, 198, 203, 208
threaded, 206207, 217220, 350
threadless, 204, 210212, 219
Box-cutter knife, 6
Brake boosters, 189, 194, 410
Brake hoses, 46, 164, 166, 173
installing, 189
Brake levers, 96, 152155, 177, 184,
255
positioning, 152154
removing, 96, 152154, 258
shift cables and, 88
squeezing, 15, 163
Brake pads, 23, 42, 126, 164, 174,
299, 410
adjusting, 151, 177, 180, 181,
188189, 193
checking, 15, 156
cleaning, 156
cottered, 155, 156, 157
disc, 155157
offset of, 177178, 182
removing, 166, 171
replacing, 166, 179180, 181, 191,
192, 193
rims and, 4041
spacing, 149, 158, 166
toeing in, 183, 191, 193194
worn, 148, 150, 193
Brake reach, adjusting, 154155
Brakes, 23, 24, 152, 154, 170171,
173, 183, 185, 186, 410
bleeding, 168170
checking, 15, 16, 22
curved-face, 183
cylindrical-arm, 183
423
424
cylindrical-clamp, 182
disconnecting, 328, 331
feel of, 184
Hayes, 157, 159, 168170, 173
hub, 414
linkage, 148, 190, 194
mounting, 162-163
opening, 4041
options for, 147148
releasing, 1617, 23, 148, 150
rim, 16, 149, 150, 301
rubbing, 370
Shimano, 8889, 95, 167, 185
troubleshooting with, 192194
See also Cantilever brakes; Disc
brakes; Hydraulic brakes;
Roller-cam brakes; U-brakes;
V-brakes
Braking, 291, 322
chattering/vibration when, 183,
369, 372, 374, 375
problems with, 369370
Brushes, 24, 26
Buckets, 24
Bushings, 180, 181, 211, 231, 234,
330, 334, 335, 353, 354, 355,
356, 358, 361, 410
replacing, 359360
Cable cutters, 6, 86
Cable stops, 348, 410
Cable tension, 72, 7678, 107
adjusting, 71, 74, 85, 148149, 151,
152, 186, 230231, 396
Cables, 76, 97, 148154, 178, 185,
190, 251, 311, 410
broken, 4546
clamping, 4041
Gore-Tex, 86, 94, 95, 178
installing, 22, 74, 9293, 94, 150
loose, 4041, 85
lubricating, 30, 9495, 107, 149,
150
maintaining, 103, 149, 152, 192
replacing, 30, 85, 8792, 149, 150,
152
shift, 80, 85, 88, 8990
Shimano, 8990
sticky, 68, 107
tying, 43
worn, 151, 193
Calipers, 11, 41, 150, 156, 163, 170,
313, 410
cleaning, 171173
disc-brake, 31, 161, 162, 173174
hydraulic, 156, 171173

measuring, 415
mounting, 161162
overhauling, 173174
postmount, 163
Cantilever brakes, 16, 22, 31, 41,
147148, 149, 150, 151, 175180,
411
curved-face, 183
overhauling, 180187
sidepull, 417
Cantilevers, 147, 148, 150, 151, 152,
194, 417
Carbon-grip compound, 9
Cartridge bearings, 103, 133136,
208, 219, 231, 276, 279, 280,
286, 358, 359, 411
angular-contact, 277, 278, 281
cleaning, 133134
lubricating, 31
See also Ball bearings
Cartridge-removal tool, 340
Cartridges, 208, 352
air ination, 35
Centering, 126, 178179, 301303
Chain cleaners, 26, 5354
Chain elongation, checking for,
5556, 67, 69
Chain-elongation gauges, 3, 5556,
69
Chain gap, 7879
Chain keepers, 7
Chain length, determining, 5759, 73
Chain links, 411
loosening, 67
replacing, 38, 56, 60
spacing between, 66
spare, 13
tight/stiff, 66, 67
twisted, 3638
Chain retention devices, 100101
Chain stops, 110
Chain suck, 6667, 107, 201, 370, 411
Chain tensioner, 101
Chain tools, 23, 12, 33, 38, 42, 56,
59, 61, 62
Chain whips, 6, 7, 138, 139, 140, 141,
142, 411
Chainlines, 85, 107108, 224, 411
measuring, 108110
Chainring bolts, 195, 201, 202, 222
Chainring-cassette removal tools, 6
Chainring-nut tools, 6, 202, 411
Chainrings, 27, 37, 4245, 51, 53, 55,
57, 58, 60, 64, 65, 195, 197202,

216, 411
bent, 201
chainstays and, 223225
cleaning, 26, 66, 200
inner, 109, 223
inspecting, 66, 200201
installing, 66, 202
jammed chains and, 36
loose, 221
maintaining, 200
middle, 10
spindles and, 209
worn, 200
Chains, 411
assembling, 5152
broken, 38, 54, 56, 57, 59
cleaning, 2627, 5255, 66
connecting, 57, 5961
dropping, 110, 370
jammed, 15, 3638, 370
lubricating, 4, 13, 2526, 27, 30,
5154, 66, 67, 74, 105, 254
maintaining, 152
measuring, 140
removing, 27, 44, 45, 5457, 63
replacing, 55, 62, 67, 68, 74, 150
Shimano, 26, 56, 59, 6061, 62
skipping, 67, 107, 370
slapping, 370, 372
squeaking, 67
SRAM, 54, 56, 61, 62
troubleshooting, 6669
with twisted link, 3738
wiping, 25, 26, 27, 30, 5253, 67
Wippermann, 37, 54, 56, 62, 67, 69
Chainstays, 23, 40, 43, 65, 66, 74,
81, 102, 103, 109, 159, 213, 349,
361, 367, 411
chain suck and, 67
chainrings and, 223225
jammed chains and, 36
Circlips, 208, 211, 212, 220, 313, 327,
336
Clamps, 58, 81, 82, 83, 254, 255, 276
cylindrical, 182
saddle, 245, 246
seatpost, 31, 46, 253, 254
split, 153
See also Stem clamps
Cleats, 226, 230
adjusting, 227229, 240
installing, 227229
loose, 239240
Clunking noises, problems with,
222223, 372
Cog-wear indicator gauge, 11

Cogs, 51, 55, 58, 64, 73, 74, 75, 77,
78, 79, 108, 111, 127, 137146,
209, 411
cassette, 138141
checking, 6768
cleaning, 26, 53, 138, 139, 140
removing, 68, 102, 138, 139, 140,
145146
replacing, 68, 139, 140, 141
worn, 67, 139, 140
Compression, 316, 357, 358, 361
Compression damping, 321322,
362, 365, 366, 411
adjusting, 316, 323, 325, 364
Compression rings, 273, 276, 278
Concentric-pivot systems, 43, 65,
102
Cones, 6, 127, 128133, 213216,
221, 222, 223, 236, 237, 409, 411
Crank bolts, 195, 197, 199, 200, 222,
411
Crank extraction tools, 197
Crank pullers, 6, 195, 198
Crankarms, 84, 195, 197202, 210,
211, 216, 217, 221, 225, 226, 227,
244, 363, 385, 411
length/determining, 388
loose, 222223
removing/installing, 202, 212,
215, 218
Cranks
custom, 388
hard-to-turn, 223
integrated-spindle, 195, 197,
198199, 203, 204, 205
length, 390, 411
removing/installing, 195, 197200
Shimano, 197, 199, 202, 207
square taper, 197, 199
Cranksets, 195, 210, 412
BB30: 204, 219
external-bearing, 207
lubricating, 31
three-piece, 197, 199, 203, 204,
207209
Truvativ, 209, 210, 218, 219
two-piece, 203, 207
Creaking noises, 372
bottom bracket, 221222
crank, 221222
handlebar, 287
pedaling, 207, 239240
seatpost, 254
Crowfoot sockets, 11, 412

Crown-race punches, 285
Crown-race removers, 11, 283, 284
Cup removal tools, 7
Cups, 412
adjustable, 207, 215, 216, 221, 409
bearing, 207, 211, 212, 409
bottom bracket, 30, 83, 213, 217,
223, 350
xed, 214, 413
Damping, 318, 357, 412
adjusting, 325326, 327, 334
changing oil and, 336338,
355356
compression, 316, 321322, 323,
325, 362, 364, 365, 366, 411
hydraulic, 262, 309310, 314
preload, 363364
pressurizing, 358
rebound, 318, 320321, 323, 325,
361, 362, 364, 365, 366, 416
Damping adjusters, 326, 327, 334,
365
Damping systems, 325, 336338
Derailleur cages, 42, 68, 84, 107
Derailleur-hanger alignment tools,
11, 68, 349
Derailleurs, 23, 27, 47, 57, 7180,
8085, 209, 412
adjusting, 68, 71, 7480, 8385,
200
bent, 43, 68, 107
bottom-pull/top-pull, 82
broken, 71, 103
bypassing, 44
cables and, 82, 85, 9294
chain length and, 57
disassembling, 88, 106
down-swing, 81
E-type, 81, 8283, 209, 213, 223
installing, 7374, 8283
lubricating, 30, 105
maintaining, 26, 53, 103106
positioning, 83, 84, 107
repairing, 4244
replacing, 69, 79, 105, 106
Shimano, 45, 46, 71, 73, 7475,
76, 77, 79, 8283, 84, 87, 88, 92,
106, 107, 213
spokes and, 370, 372
SRAM, 78, 82, 87, 106, 107
top-swing, 81, 224
worn, 67, 107
Disc-brake pads, checking/replacing, 155157

Disc brakes, 17, 22, 31, 147, 148, 152,
155164, 166175, 192, 412
cable-actuated, 155
overhauling, 171174
Dishing, 301303, 349, 367, 412
Dishing tools, 7, 301, 302, 412
Drills, 11
Drivetrains, 60, 65, 74, 101, 107, 292,
412
cleaning, 2426
wear/tear on, 55
Dropout-alignment tools, 11, 341
343, 342, 344, 367368
Dropout Saver, 351
Dropouts, 18, 20, 23, 24, 65, 66, 71,
73, 78, 102, 109, 128, 309, 311,
349, 412
aligning, 68, 342343, 344, 366
aluminum/titanium, 368
bent, 80, 312, 344
bolt-on, 367
inspecting, 348
sliding, 58
spacing, 341, 342
thickness of, 351
Duct tape, 14
Dust caps, 144, 199, 200, 236, 237,
239, 412
Dust covers, 143, 237
Easy-outs, 354, 412
Elastomers, 249, 262, 309, 311, 314,
315, 318, 319, 324326, 327,
331, 361, 412
End caps, 86, 152, 410, 412
Fasteners, torque for, 396407
(table)
Feeler gauges, 11
Files, 6
Firmly tightened, 29, 395
Foot pounds (ft-lbs), Newtonmeters and, 397
Fork braces, 311, 315
Fork-crown race punch, 7
Fork-crown race remover, 283
Fork-crown races, 281, 282284,
285286
Fork crowns, 309, 310, 311, 312, 313,
315, 413
clamping, 268
INDEX
425
426
fork legs and, 316, 327328

Fork legs, 40, 309, 311, 315, 325
damaged, 313
fork crowns and, 316
removing, 327328
telescoping, 310
Fork rake, 309, 413
Fork travel, 319
changing, 323, 338-339
measuring, 315317
Forks, 16, 18, 115, 289, 310, 317, 413
air-sprung, 312, 326327
alignment of, 312, 313, 314, 318,
341344
aluminum, 314, 343
carbon-ber, 314, 343
coil-spring, 311, 319, 324326, 327
double-crown, 327, 328, 330
failure of, 311, 312
headset installation and, 284285
high-end, 321, 331
inspecting, 311313, 313314
linkage, 312, 314
maintaining, 313314, 314315
Manitou, 34, 159, 331
movement of, 321, 322
overhauling, 314, 330331,
334336
rebound damping and, 321
removing, 277, 280, 282, 330331,
341
rigid, 309, 313314, 344
RockShox, 326, 327, 328, 337,
338339, 340, 357
SID, 326, 327, 337
single-crown, 327, 328
steel, 341, 344
stuck stems in, 287
suspension, 20, 31, 46, 128, 189,
263, 282, 284, 309, 310, 313,
314, 314315, 317324, 330,
384, 386
telescoping, 310, 312, 314
threaded, 265266, 267, 312
titanium, 314, 343
triple-clamp, 327328, 330
tuning, 314, 315, 317327
upside-down, 419
Frame size
body measurements and,
385388
correct, 384385
nding, 383, 386387
Frames, 31, 208, 212, 289, 413
alignment of, 366368

carbon, 347, 348
cleaning, 348
designing, 345, 347
diamond, 345, 412
headset installation and, 284285
suspension, 101102, 347, 358
361, 368, 386, 389, 390
types of, 249, 347
Freehubs, 78, 134, 137146, 413
disassembling, 144
lubricating, 142146
overhauling, 111
removing, 144, 146
seized, 47
solvents and, 142, 144
Freewheel removers, 7, 141
Freewheels, 127, 137146, 413
maintaining, 111
replacing, 68, 111, 141
seized, 47
Front triangles, 345, 347, 349, 413
Gauges, 56, 57, 68
Gear development, 375381
for 26-inch wheels, 376378
(table)
for 29-inch wheels, 381383
(table)
Gloves, 13, 55
Grease, 4, 13, 137, 201
molybdenum disulde, 94
nonlithium, 6, 92, 97, 335
silicone-based, 6
Slick Honey, 251, 335, 355, 357,
359
Teon, 92, 97
Grease guns, 6, 136, 142
Grip Shifts, 29, 78, 94, 95, 107, 258,
413
long/short, 97, 98
overhauling, 9192
replacing, 9697
Grips, 111, 255, 266
removing, 9596, 153, 257, 258
trimming, 258
Hacksaw, 6
Hammers
ball-peen, 6, 7
soft, 7
Handlebar height, 385, 388, 389390
adjusting, 266, 392

Handlebar position, 242, 244, 263,

266, 388391
Handlebar reach, 384385, 388, 390
Handlebar slips, 286287
Handlebars, 251, 255, 257, 258260,
273, 315, 325, 413
broken, 47, 260, 287
carbon, 154, 260, 393
drop, 384385
installing, 258259
knees and, 383, 384
overtightened, 259, 393
replacing, 258, 259260, 266
riser, 255, 391
saddles and, 390
twisting, 259, 266, 267
types of, 260, 266
undertightened, 393
Hangers, 13, 43, 69, 78, 80, 366, 410,
412
alignment of, 349350
bent, 68, 107, 349350
brake-cable, 271, 281
derailleur, 348, 349350, 351
straddle-cable, 184
Head angles, 309, 413
Head tubes, 277, 278, 282, 284, 286,
367, 388, 413
measuring, 268, 270
Headlights, 14
Headset cups, 286
removing, 276, 282
Headset presses, 7, 11, 285286
Headset rockets, 282
Headsets, 255, 263, 270286, 312,
313, 413
adjusting, 265, 268, 272276, 279,
282, 286, 287
cartridge-bearing, 272
cupless, 268, 277, 278, 282
installing, 284286
integrated, 270, 271, 274, 278,
284, 414
loose-ball, 278, 281
loosening, 274275
overhauling, 276282
overtightening, 275
pitted, 275, 287
press-in internal with lipped
cups, 268
replacing, 281, 282284, 287
semi-integrated, 270
threaded, 273276, 279282, 418
threadless, 269, 270272, 276

279, 285, 387, 390
tight, 272273, 274275, 287
traditional, 168, 270
Hex keys, 12, 29, 47, 414
metric, 2, 7, 20, 40, 41, 42
HG-IG check tool, 68, 139
Hose cutters, 11
Housing, 76, 77, 82, 89, 90, 92, 148
152, 185, 193, 273, 410
cutting, 11, 86, 153
friction and, 150
index-shift, 86
installing, 74, 87
lower-knuckle, 79
lubricating, 30, 85, 9495, 151, 152
replacing, 30, 152
sticky, 68
Teon-lined, 150, 151
Hubs, 102, 103, 127137, 231, 306,
414
assembling, 131132
cartridge-bearing, 127, 128,
132136
cup-and-cone, 127, 128133
DT Swiss, 28, 125, 133, 134, 142,
145
front, 127, 292
Grease Guard, 136137
high-end, 128, 136
internal-gear, 101103
lubricating, 131132
overhauling, 111, 127136
replacing/ipping, 141142
sealed-bearing, 127, 128
wheelbuilding and, 289, 291, 292,
299
Hydraulic brakes, 42, 99, 107, 148,
150, 158, 166173, 187190,
192, 193, 194, 414
bleeding, 31, 166, 168, 170, 171,
189190
disconnecting, 328
replacing pads on, 189
Hydraulic uid, 158, 166, 167, 169,
170, 171, 172, 173, 194
Hydraulic oil, 325
Inertial valves, 322, 325, 327, 365,
414
adjusting, 323, 364
Inner legs, 310, 314, 327, 334, 335,
336, 337, 339, 414
Inner tubes, 114, 122, 123, 251

nding leaks in, 115116
inating, 35, 36
patching, 36, 116
removing, 111112
spare, 2, 1213, 3435
tying knots in, 35
International Organization for
Standardization (ISO), 117, 159
Interrupted-seat-tube congurations, 387, 388
Jockey wheels, 27, 43, 58, 59, 68, 73,
74, 78, 80, 414
bolts, 106
lost, 4445
wiping, 26, 53
Knee clearance, 384
Lacing, 289, 294, 296, 297299, 306
checking, 299, 307
radial, 304305
three-cross, 304305
Leaks
nding, 115116
sealing, 122, 123, 124
Leverage, 154155, 166, 176, 177, 414
Levers, 89, 90, 150, 170, 173
lockout, 362, 364
Shimano, 8788, 99100, 107, 155
split-clamp, 153
SRAM, 87, 95, 97, 155
See also Brake levers; Quickrelease levers; Tire levers
Licktons SuperLink, 61
Limit screws, 73, 107
adjusting, 46, 71, 74, 7576, 78,
84, 85
Locknuts, 58, 133, 145, 146, 149, 152,
237, 271, 273, 275, 281, 414
loosening, 128129, 132, 151, 274
removing, 236, 280
tightening, 132
Lockouts, 316, 362, 364, 414
Lockring tools, 6, 160
Lockrings, 78, 140, 160, 207, 213,
224, 414
adjustable-cup, 223
removing, 139, 221
tightening, 215216
Loctite, 28, 68, 77, 136, 212, 222,
231, 313
Lubrication, 3031, 128, 330
ball bearing, 31, 131, 132, 281, 286
cable, 30, 9495, 107, 149, 150
chain, 4, 13, 2526, 27, 30, 5154,
66, 67, 74, 105, 254
crankset, 31
derailleur, 30, 105
fork, 31, 314
freehub, 142146
freewheel, 30, 146
housing, 30, 85, 9495, 151, 152
hub, 131132
pedal, 31, 239240
piston, 173, 190
quill, 281
saddle, 31
seatpost, 31, 254, 266, 348
shifters, 30
wheel, 30
Magnet, 7
Master cylinders, 173, 415
Master links, 13, 33, 42, 54, 57,
5960, 61, 6364, 67, 69, 415
Matches, 14, 48
Money, 14
patching sidewalls with, 36
Morningstar Drumstix tool, 175
Morningstar Freehub Buddy, 7, 142,
143, 144
Morningstar Freehub Soup, 142,
143, 144
Morningstar Rotors on Center (ROC)
dial-indicator tool, 10, 174175
Mounting bolts, 69, 105, 192, 415
Mounts
broken, 348
disc-brake, 309, 351
IS, 159, 313
ISCG, 101
Multitools, 12, 38
Needle bearings, 279, 280, 415
Newton-meters (N-m), foot-pounds
and, 397
Nipples, 124, 127, 290, 292, 293, 294,
307308, 415
tightening/loosening, 125, 299,
300, 301, 302, 303
types of, 126, 291, 308
O-rings, 144, 158, 164, 172, 337, 354,
355, 357, 362363
Off-center rims (OCR), 292, 293, 308
INDEX
427
428
Outer legs, 310, 312, 315, 323, 328,

330, 334, 415
Oversteering, 319, 322, 324
Overtightening, 259, 272, 275, 393
Pad spacers, 12, 190
Pad swing, 182
Pad-to-rim adjustment, 176178,
187, 189, 192
Pad twist, 182
Parts washer, 7
Patch glue, 116
Patch kits, 2, 12, 3435, 36, 116
Patches, 35, 36
applying, 116118
Pedal overlap, 385, 415
Pedal platforms, 317, 321, 322, 325,
362
Pedaling, 308, 311, 317, 322
creaking with, 207, 375
knee/joint pain while, 240
resistance while, 58, 371
stance, 415
Pedals, 235, 415
cage-type, 225
clip-in, 225, 226, 227231,234,
236, 240, 371, 411
clunking by, 371
Crank Brothers, 228, 229, 230,
234, 238, 239
at, 225
Look, 228, 229, 230, 231, 232233,
234, 235, 238
loose-bearing, 31, 236237,
Onza, 230231, 238
overhauling, 231232, 234239
play in, 223, 371
release tension for, 227, 229231,
371
removing, 226227
Ritchey, 232, 235, 238, 239
Scott, 235
Shimano, 231, 232, 234, 235
Speedplay, 229, 231, 234, 235, 240
Time, 228, 229, 230, 231, 232, 234,
235, 238, 239, 240
Pedros Green Fizz, 24
Pedros Ice, 31
Pedros Syn Lube, 30
Phil Wood Tenacious Oil, 145
Pin spanners, 7, 29, 215, 216, 221,
415
Pistons, 166, 337, 338, 356, 358
cleaning, 172173
disc-brake, 157158
lubricating, 173
pushing back, 157158
Pivot bolts, 415
Pivots, 154, 155, 194, 312, 313, 415
bushing, 31
derailleur, 69, 79
loose, 107
overhauling, 105
Pliers, 2, 14, 37
Channel-lock, 6
master-link, 7, 63, 64
snapring, 6
Vise-Grip, 63
Postmounts, 159, 161, 163, 309, 313,
351
PowerLink, 61, 63, 64
Preload, 319, 322, 324, 362, 363
Preload adjusters, 331, 362,
363364
Press t systems, 204, 205, 220
ProGold ProLink, lubricating with,
51, 67
Pulling, problems with, 369
Pumps, 2, 12, 35, 124
oor, 120
shock, 4, 12, 326
Punctures, 15, 16
xing, 3436
preventing, 3334
snakebite, 34, 35, 120, 124
Quick-release (QR), 416
Quick-release (QR) levers, 148, 188
Quick-release (QR) seatpost binders, 248, 388
Quick-release (QR) skewers, 20, 22,
34, 45, 139, 142, 342
checking, 15
installing, 132
opening, 1718
removing, 128, 141
tightening, 19
Quills, 265, 416
lubricating, 281
Race Face, 197, 199, 210, 416
Races, 127, 136, 409, 416
fork-crown, 281, 282284,
285286

Rags, 4
Rattling noises, 287
Really tight, 30, 396
Reamers, 11
Rear triangles, 43, 65, 102, 342, 345,
416
Rebound damping, 318, 320321,
361, 362, 364, 416
adjusting, 321, 323, 325, 365, 366
Release tension adjustment, 227,
229231, 240, 371
Ride height. SeeSag
Rim strips, 35, 118, 121
Rims, 16, 121, 149, 150, 416
bent, 41, 111
brake pads and, 4041
cleaning, 192193, 303
deep-section, 112
disc-brake, 301
drilling, 308
examining, 120
off-center, 292, 293, 308
replacing, 291
scraping, 125, 299, 300
spokes and, 124127
tubeless, 293
wheelbuilding and, 289, 292, 294
Roller-cam brakes, 17, 150, 190,
191192, 194, 416
Rotors, 127, 304
bent, 175
bolting, 160161
cleaning, 193
installing/removing, 159161
splined, 159, 160, 161
truing, 4142, 174175
Rubbing alcohol, 4, 257
Rubbing noises, problems with, 373
Saddle height, 240, 243, 248, 388
Saddle position, 242, 244, 246, 247,
253, 388389
Saddles, 391, 416
adjusting, 243
choosing, 241242
clamping, 245
handlebars and, 390
installing, 245246, 247248
lubricating, 31
maintaining, 242
shape/design of, 242
troubleshooting problems with,
253254
Sag, 315, 319, 324, 361, 366, 416
measuring, 316317, 318
setting, 362363
Saw guide, 263
Scraping noises, problems with, 373
Screwdrivers, 12, 42, 43, 45, 46
bent-shaft spoke-nipple, 10
Phillips-head, 2
Sealants, 9, 16, 34, 35, 120, 122124,
417
aerosol, 123
glycol-based, 122, 123
latex-based, 122
tubeless tires and, 121, 123124
Seals, 173, 178, 216, 217, 328, 330,
356, 357, 359
bearing, 136, 277
cleaning, 354355
quad, 355
removing, 218, 355
square, 158, 355
Seat bags, 33, 42
Seat tubes, 45, 80, 82, 248, 249, 254,
367, 416
length of, 386, 387
Seatpost clamps, 31, 46, 253
lubricating, 254
Seatposts, 241, 243, 384, 389, 417
adjusting, 249251
aluminum, 245, 252, 253, 254
broken, 47
carbon, 245, 251252
Crank Brothers, 249, 250, 251, 388
extensions, 244
GravityDropper, 249, 250, 251, 388
height-adjustable, 249251, 388
lubricating, 31, 254, 348
maintaining, 244245
Maverick, 249, 250, 251
position of, 244, 250
removing, 46, 244, 248, 251253
single-bolt, 246
stuck, 251253
suspension, 244245, 249, 254
troubleshooting problems with,
253254
two-bolt, 246, 247
Seatstays, 23, 65, 349, 367, 417
Setscrews, 29, 79, 98, 106, 133, 185,
186, 191, 248, 331, 349
Shifters, 92, 95103, 255
derailleurs and, 107
dual-lever trigger, 152
friction, 413
indexed, 7678, 414

lubricating, 30
maintaining, 97103
removing, 258
replacing, 9091, 96
Shimano, 77, 88, 96, 177, 416
SRAM, 9091, 95, 107
thumb, 8788, 97, 100, 418
twist, 9091, 9697, 98, 99, 103,
153, 154, 419
Shifting, 371
adjusting, 73
checking, 16
optimizing, 78, 95
ramps, 200
Shimano Pedaling Dynamics (SPD),
226
Shimmying, 369
Shims, 78, 82, 163, 356, 417
Shocks, 310, 356, 358, 363
air, 361, 362
coil spring, 361
deating, 353
downhill courses and, 365366
elastomer, 361, 362
inspecting, 348349
installing, 355
removing, 353354
saddle, 241
Shoes, 225, 228
Shop, well-stocked, 911
Shuddering, while braking, 183
Sidewalls, 114
patching, 36, 121, 122, 124
Skewers, 133, 135, 417
bolt-on, 18, 20
quick-release, 15, 1718, 19, 20,
22, 34, 45, 128, 132, 139, 141,
142, 342
tightening, 19, 20
Slick Honey grease, 251, 335, 355,
357, 359
Slime, 34, 417
Snug, 29, 395
Solvents, 130
citrus, 53, 54, 55, 105, 135, 221,
277, 280
freehubs and, 142, 144
using, 2627, 54
Spacers, 128, 132, 157, 159, 213, 263,
265, 274, 276, 278, 279, 315,
323, 417
adding, 209
internal, 339340
removing, 129
Spacing, 66, 149, 166, 341, 342, 344,
349
brake pad, 158
crank-to-frame, 224
pad-to-rotor, 163
problems/remedying, 7778
Spanners, 417
pin, 7, 29, 215, 216, 221, 415
toothed-lockring, 29
Spiders, 102, 201, 417
Spindle removal tool, 6
Spindles, 109, 210, 227
bottom-bracket, 66, 203, 209,
211212, 223
chainrings and, 209
installing, 212
integrated, 195, 197, 198199, 203,
204, 205, 216, 217
pedal, 6, 227
splined, 207
square-taper, 207
upgrading, 239
Splines, 29, 140, 141, 160, 207, 417
Spoke calculator, 290, 291
Spoke-prep compound, 291
Spoke tension, 10, 124, 292, 301
reducing, 308
Spoke-tension gauge, 10
Spokes, 76, 290, 417
adjusting, 39, 40, 127, 299, 300,
301, 302, 303
broken, 3940, 41, 124, 126127
converging parallel, 299
crossing, 299, 307
derailleurs hitting, 370
rst set of, 293294, 305
fourth set of, 297299, 306
Kevlar, 40
lacing, 289, 294, 296, 297299
length of, 290
prestressing, 302, 303
pulling, 293, 303, 308
radial, 308
replacing, 3840, 126127, 291
rims and, 124127
second set of, 294295, 305306
spare, 13, 40
thickness, 290, 307308
third set of, 296297, 306
twisted, 125
weaving, 126127
Spoking patterns, 308
one-cross, 289, 291, 306307
INDEX
429
430
radial, 291, 293, 303305

three-cross, 289, 291, 297, 304
306, 418
two-cross, 289, 291, 306307
Spring preload, 318, 319, 324, 363,
417
Spring rate, 318, 319, 320, 324, 362,
365
adjusting, 108, 323, 366
Spring tension, 178179, 191
adjusting, 185186
Springs, 230, 356, 365, 366, 417
air, 251, 314, 324
coil, 314, 315, 319, 320, 324325,
331
increasing tension of, 66
negative, 326, 327, 363
positive, 326
removing, 315316
soft, 318
stiff, 318
Squeaking noises, 372, 373
with saddles, 254
Squealing noises, 373
with breaking, 157, 373
Stand-over height, 345, 383, 384,
386, 387, 418
Stans No Tubes tubeless system,
120121, 418
Star-nut installation tools, 7, 274
Star nuts, 263, 264, 274, 279, 418
Steering
axis, 309, 418
stiff, 372
systems, 111, 255
Steering-tube overlap, 263, 278
Steering tubes, 267, 268, 270, 271,
273, 275, 276, 278, 279, 280,
281, 283, 284285, 309, 310,
311, 418
carbon, 263, 264, 274
clamping, 282
cutting, 285
fork alignment and, 341, 342343,
344
lubricating, 266
stripped threads on, 313
stuck stems in, 287
threaded, 260, 312, 313
threadless, 260, 262265, 312
Stem bolts, 265, 282, 287
Stem clamps, 259, 262, 263, 265,
268, 270, 279, 287, 312
spreading, 267
tightening, 274
Stem length, 263, 285, 388, 390, 418

Stem wedges, 265, 270
Stems, 255, 260, 262268, 273, 275,
278, 285, 418
adjusting, 262266, 268, 385
broken, 266
checking, 16
clamp-type, 262, 267
front-opening, 258
installing, 262266
quill-type, 265, 281, 416
removing, 260, 262, 265, 266268,
280
stuck, 266268, 287
suspension, 262
torque on, 393
Stopscrews, 45, 80
Straddle cables, 190191, 418
adjusting, 184185
Subpins, 57, 59, 60, 61
Suspension, 111
aligning, 343
cables and, 150
fork, 20, 31, 46, 128, 189, 263, 282,
284, 309, 310, 313, 314315,
317324, 330, 384, 386
frame, 101102, 347, 358361,
368, 386, 389, 390
maintaining, 249
problems with, 372
rear, 43, 47, 81, 108, 128, 147, 318,
347, 361365
seatpost, 244245, 249, 254
stem, 262
tuning, 361365
Swingarms, 23, 82, 347, 348349,
351, 358, 363, 367, 418
Syringes, 7, 171, 189, 190, 338
Talcum powder, 2, 118
Tension gauge, 66
Third Eye Chain Watcher, 110
Threadlock compound, 201, 293,
313, 330, 394
Threads
xing damaged, 350
prepping/tightening, 2728
Through-axles, 2022, 23, 128
quick-release, 20, 21
removing/installing wheels with,
20
Thumb shifters, 97, 100, 418
replacing cable in, 8788
Tight, 29, 395

Tightness, 2930, 393

Tire beads, 114, 115, 119, 120, 121,
418
Tire inators, 13, 267
Tire levers, 2, 12, 114, 158, 418
Tire pressure, 6, 16, 120, 318
Tires
checking, 16, 118
deating, 113, 116, 120, 123, 124
diameter of, 375
at, 15, 16, 3334, 112, 372, 374
inating, 113, 120, 122, 124
removing, 111112, 114, 115, 342
size of, 117
standard, 120121, 122
tubeless, 34, 111, 114, 115, 116,
120121, 122, 123124
Toeclips, 225
Toeing in, 183, 191, 193194
Tool kits
Level 1: 14, 14
Level 2: 1, 4, 6
Level 3: 1, 7, 9
Tools, 1, 31, 54, 90, 163, 223, 417
carrying/while riding, 1114, 33,
48
Enduro, 218, 219
Mavic, 216
Phil Wood, 218
Shimano, 61, 62, 199, 285
terminology of, 72
Top tubes, 387, 388, 419
Torque, 199, 200, 419
for fasteners, 396407 (table)
measuring, 393, 395
recommendations on, 397
setting, 394
tightening, 2930, 395
Triple-clamp forks, 327328, 330
Truing, 41, 124, 127, 303
lateral, 125, 299301
radial, 301
side-to-side, 301
Truing stands, 7, 124, 126, 299, 300,
301, 302
Tubes. See Inner tubes
Tubing cutters, 11
Twist shifters, 9091, 9697, 98, 99,
103, 153, 154, 419
U-brakes, 16, 22, 148, 190191, 194,
419
Understeering, 322, 324
Undertightening, 393
V-brakes, 16, 17, 22, 31, 147, 148,

149, 152, 154, 155, 183, 190,
194, 419
adjusting, 176179
installing, 176179
overhauling, 175180
parallel-push, 178, 179
Valve core removers, 7, 357, 358
Valve cores, 113, 123, 356, 357
Valve extenders, 112, 113
Valve stems, 113, 114, 115, 119, 120
Valves, 115, 120
broken, 35
Presta, 34, 45, 112, 113, 114, 115,
118, 121, 123, 415
Schrader, 4, 34, 112, 115, 251, 320,
326, 327, 353, 416
Vibrations, braking and, 369
Vise, 6, 7
Vise grip, 6
Vise whips, 7, 138, 139, 141, 142, 419
Wheel-retention devices, 21, 419

Wheelbuilding, 40, 289290, 303,
307308
custom, 289
disc-brake, 291
front, 291, 293, 294
rear, 291, 293
Wheels, 343
bent, 3841, 369
for big riders, 307308
centering, 301303
disc-brake, 291, 292, 294, 303,
305306
heavy-duty, 289
lubricating, 30
prestressing, 302
removing/installing, 16, 1724,
111, 115, 128, 133, 150, 163, 166,
341, 342, 367
straightening, 3841
truing, 40, 124126, 299301
Wire, 14
Wrenches
adjustable, 2, 37, 113
Allen, 29, 409
cone, 6, 128, 132
crowfoot, 11, 412
xed-cup, 223
headset, 6, 14, 274
metric, 2, 20
open-end/box-end, 2, 12, 29
pedal, 13-14, 226
socket, 6, 29, 417
soft, 7
splined, 7, 9, 29
spoke, 4, 7, 13, 39, 40, 41, 124,
291, 299
torque, 7, 20, 200, 210, 229, 312,
393394, 419
Torx, 6, 12, 29, 42, 201, 202, 419
Y-, 9
INDEX
431
About the author

Lennard Zinn is a bike racer, frame builder, and technical writer. He grew up cycling, skiing, whitewater
rafting, and kayakingas well as tinkering with mechanical devicesin Los Alamos, New Mexico. After
receiving his physics degree from Colorado College, he became a member of the U.S. Olympic Development
Cycling Team. He went on to work in Tom Ritcheys frame-building shop and has been producing custom
mountain, road, and triathlon frames, as well as custom cranks and stems, at Zinn Cycles since 1982
(www.zinncycles.com).
Zinn has been writing for VeloNews since 1989 and is the magazines senior technical writer. Other books
by Zinn are Zinn & the Art of Road Bike Maintenance (VeloPress, 3rd ed. 2009), Zinn & the Art of Triathlon Bikes
(VeloPress, 2007), Zinns Cycling Primer (VeloPress, 2004), Mountain Bike Performance Handbook (MBI, 1998),
and Mountain Bike Owners Manual (VeloPress, 1998).
ABOUT THE ILLUSTRATOR

Todd Telander is a former mechanic and bike racer who devotes most of his time these days to artistic endeavors. He attended the University of California at Santa Cruz, and while earning degrees in
Environmental Studies and Biology, he completed a graduate-level program in scientific illustration.
He has since studied fine art in several western states and was awarded an artists residency at Rocky
Mountain National Park. In addition to drawing bike parts, he paints and draws wildlife and landscapes
for publishers, museums, design companies, and individuals. You can see more examples of his work on
his website, www.toddtelander.com.
Also available from VeloPress

Zinn & the Art of Road Bike Maintenance
3rd Edition
Lennard Zinn applies his prodigious powers of mechanical expertise to the art and science of
road bike repair. Newcomers and experienced mechanics alike will benefit from the books
hundreds of illustrations (including exploded views of how components go together), its step-bystep instructions for basic and advanced repair, and Zinns practical, time-saving maintenance
tips. Covers new and old bikes alike.
440 pages $24.95
ISBN 978-1-934030-42-4
Zinn & the Art of Triathlon Bikes

Aerodynamics, Bike Fit, Speed Tuning, and Maintenance
More than a repair manual, Zinn & the Art of Triathlon Bikes presents proven techniques to wring
more speed from todays triathlon bicycles. With clear advice on bike fit and comfort, getting
aero, tuning for speed, and choosing wisely among equipment upgrades, the tips in this book
virtually guarantee faster bike splits. Of course, Zinn includes comprehensive maintenance and
repair instructions too, accompanied by more than 300 illustrations and step-by-step directions
to ensure trouble-free rides.
352 pages $24.95
ISBN 978-1-931382-97-7
Zinns Cycling Primer

Maintenance Tips & Skill Building for Cyclists
Drawing upon the research of cycling experts around the world, Zinns Cycling Primer is a onestop guide for improving your riding skills. Covering all aspects of road and mountain cycling,
Lennard Zinn shows you how to improve your bike fit and bike handling skills, as well as your
training and recovery, injury prevention, core strength, and nutrition. Zinn also includes step-bystep instructions for basic road and mountain bike maintenance, repair, and upgrades.
232 pages $24.95
ISBN 978-1-931382-43-4

Zinn & The Art of Mountain Bike Maintenance

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Zinn & the Art of Mountain Bike Maintenance, 5th edition

Text copyright 2010 by Lennard Zinn

All rights reserved. Printed in the United States of America.

1830 55th Street

Distributed in the United States and Canada by Ingram Publisher Services

Cover and interior design by Erin Johnson

Basic Stuff: Preride inspection, wheel removal,

Emergency Repairs: How to get home when

Transmission: Front and rear derailleurs, cables,

Wheels: Tires, rims and spokes, hubs, cassettes,

Brakes: Cables, levers, and calipers

Saddles and Seatposts

Handlebars, Stems, and Headsets

Mountain Bike Fitting

About the Author and Illustrator

Peace of mind isnt at all superficial, really. Its the

ABOUT THIS BOOK

ticular way, and to have one without the other

This book is intended for people who have an

would be missing out on half the fun.

interest in maintaining their own mountain

The romantic can appreciate how success at

bikes. I have written it for mountain bike owners

bike mechanics requires that the procedures be

who do not think theyre capable of maintain-

done with love, without which the care you imag-

ing their own bikes, as well as for those who do

ined putting into your mountain bike would be

and who want the how-to details at their finger-

lost. And even the pure romantic can follow the

tips. In Zen and the Art of Motorcycle Maintenance,

simple step-by-step procedures and exploded

Robert Pirsig explores the dichotomy between

diagrams in this book (of which Fig. I.1 is an

the purely classical and purely romantic views

extreme example and is the only one not intended

of the world, a dichotomy that also applies to

to be simple and clear!) and discover a passion for

mountain biking. Riding a mountain bike is

spreading new grease on old parts.

generally a romantic experience of emotion,

Zinn & the Art of Mountain Bike Maintenance is

inspiration, and intuition, even when solving the

organized in such a way that you can pick main-

complex physics of how to negotiate a technical

tenance tasks appropriate for you. The repairs in

section of trail without putting your foot down.

these pages require no special skills to perform;

Mountain bike mechanics, however, is a purely

anyone can do them. It takes only a willingness

classical structure of underlying form dominated

by reason and physical laws. The two practices

Mountain bikes are admirably resilient mach-

bike riding and bike maintenancefit eloquently

ines. You can keep one running a long time just

together. Each is designed to function in a par-

by changing the tires and occasionally lubricating

the chain. Chapter 2 is about the most minimal

my bike that I do not understand well enough to

maintenance your bike requires. Even if that is

know whether it is likely to last the ride or how to

the only part of this book you end up using, youll

fix it if it does not.